Gear Product News - Harmonic Drive Gears

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GRINDING NEWS Gear Tooth Honing Bore Finishing
Basics: Harmonic Drive Gearing Retroﬁtting Maag Gear Shapers
GEAR GRINDING
& FINISHING
April 2006
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www.gearproductnews.com
T
he Genesis
™
series of gear production machines
is the next generation in gear production
technology. The Genesis 130H
Hobbing and 130SV Shaving bing and 130SV Sha bing and 130SV Sha
Machines are available today to
deliver more speed, greater
precision and, above all, reduced
cost in day-to-day operation for
gears as larg as lar as lar e as 130 mm diameter.
Only Genesis offers:
• Workpiece load /unload times as
short as 2 seconds. • The ability to
more effectively operate in wet or
completely dry conditions (Hobber). • New hobhead
and shaving head designs to help guarantee reliability
and reduce cycle times. • A common
platform that improves performance tf tf
and simplifies installation and
serviceability. • A host of operator-
and maintenance-friendly features
making every Genesis machine easier
to own and operate.
Only Genesis combines Gleason's
long tradition of innovation and
technology leadership. Put it to
work today.
KEEPING THE WORLD IN MOTION
™
Visit www VV .gleason.com/genesis today enesis toda enesis toda to find out more. to f to f
venue, P.O. Box 22970, Rochester, NY 14692-2970 USA Phone: 585/473-1000 Web site: www.gleason.com E-mail: [email protected] 1000 University A 1000 University A
f e a t u r e s
April 2006 Gear Product News 1 April 2006 Gear Product News April 2006 Gear Product News
Cover photo courtesy
of Kapp Technologies.
� � � � � � �
www.gearproductnews.com
Grinding News
Our focus on grinding and finishing
15
Gear Tooth Honing: Economical
And Flexible
Präwema machines at Getrag Ford
24
Honing: The Secrets Of
Hole Finishing
There’s more to gears than just the teeth
28
Basics Of
Harmonic Drive
Gearing
Do you know how it works?
32
Upgrade Your
Maag Gear Shaper
Options for upgrading the controls
38
2 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
d e p a r t m e n t s
Editorial
Publisher & Editor-in-Chief
Michael Goldstein
Managing Editor
William R. Stott
Associate Editor
Joseph L. Hazelton
Assistant Editor
Robin Wright
Art
Graphic Designer
Kathleen O’Hara
Advertising
Advertising Sales Manager
Ryan King
powertransmission.com Sales
Clark Hopkins
Circulation
Circulation Manager
Carol Tratar
Internet
Web Developer
Dan MacKenzie
Contacts
Randall Publishing, Inc.
P.O. Box 1426
1425 Lunt Ave.
Elk Grove Village, IL 60007
Phone: (847) 437-6604
Fax: (847) 437-6618
� � � � � � �
www.gearproductnews.com
Product News
The latest products for the gear industry
5
Industry News
What’s happening in the gear industry
42
Classifieds
Our product & service marketplace
47
Advertiser Index
Contact information for gear industry suppliers
48
classi fi eds
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www.gearproductnews.com
The complete issue,
every issue, always available online
Plus
● Subscriptions
● Advertising Information
● FREE Buyers Guide Listings
Bookmark Us Today!
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A/WSystems Co. is your quality alternative manufacturing source of
spiral gear roughing and finishing cutters and bodies.
We can also manufacture new spiral cutter bodies in
diameters of 5" through 12" at present.
A/W can also supply roughing and finishing cutters for
most 5"–12" diameter bodies.
Whether it’s service or manufacturing, consider us as an
alternative source for cutters and bodies.
You’ll be in for a pleasant surprise.
1901 Larchwood
Troy, MI 48083
Tel: (248) 524-0778 • Fax: (248) 524-0779
Experts in CNC controlled
tooth by tooth submerged process
gear hardening. We specialize in
precision induction hardening of all
power transmission components.
Registered to TS16949:2002
standards.
Magnum Induction Inc.
14 AshDrive • Smiths Creek, MI 48074
Ph: 810.364.5270 • Fax: 810.364.4114
Email: [email protected]
magnuminduction.com
“GEARS
FOR A YEAR”
Puts your
message here
... and in
Gear Technology
... and
Online at
geartechnology.com
or
powertransmission.com
Call
Ryan King
at
(847) 437-6604
Ryan King
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We do.
See the BIG PICTURE?
How do we do this? Offer the highest quality machines, tools and processes
and then back them up with a lifetime commitment of superior service.
Leading the world in the technology of CBN, KAPP designed the first CBN
profile grinding wheel in 1981. Since then we’ve continued to improve application
capabilities, form accuracy and delivery time. That’s how we got to be THE BEST.
Our business is to help make your business succeed.
KAPP Technologies 2870 Wilderness Place Boulder, CO 80301
Ph: 303-447-1130 Fx: 303-447-1131
www.kapp-usa.com [email protected]
KAPP ) niles
One partner for all gear tasks.
0408_Sigma_Anzeige 11.04.2005 14:22 Uhr Seite 1
April 2006 Gear Product News 055 April 2006 Gear Product News
product news

Samputensili’s
Master Gears
PERSONAL I Z ED
T O CUST OMER/ DI N
SPECI F I CAT I ONS
Samputensili has introduced a range of
master gears used to determine work
gear accuracy and setting masters to
adjust checking equipment.
According to the company’s press
release, the Samputensili software
and manufacturing methods deliver
products to customer speciﬁcations
or DIN standards. Master gears allow
checking of internal or external spur
and helical gears with or without proﬁle
corrections.
When checking parts, the master gear
ﬂank rotates in contact with the work
gear teeth and primarily checks meshing,
center distance and runout, detecting
any nicks. Setting masters, conversely,
are usually static. Two master gears for
different applications and consequently
of different design can check the same
workpiece correctly. The company’s
production range includes master gears
from module 1 to module 6 with outside
diameters from 40–300 mm, tooth face
widths from 4–100 mm and helix angles
from 0–45°.
All master gears are produced in high
speed steel or bearing steel without
surface coating, depending on customer
speciﬁcations. The company says it
mainly uses powder metals, high speed
steels ASP23 and ASP30. 
For more information:
Samputensili S.p.A.
c/o Star SU LLC
5200 Prairie Stone Pkwy., Ste. 100
Hoffman Estates, IL 60192
Phone: (847) 649-1450
E-mail: [email protected]
Internet: www.star-su.com
Neeter Drive
Gearboxes
T RANSMI T POWER UP
T O 6 , 6 0 0 N- M
The PowerGear range of bevel gearboxes
from Neeter Drives is available in
sizes 360 and 450 with an extended
transmission range of 3,750 N-m for
the 360 and 6,600 N-m for the 450.
Neeter Drive says these sizes extend
the PowerGear range’s torque capacity
by a further 3,400 N-m. This is
complemented by uniform load
distribution on the gear teeth that is
set by optimizing the contact pattern
during assembly. Both gearboxes are
available with six gear ratios up to 5:1 as
standard, and each design has solid and
hollow shaft variants up to four-way
shaft conﬁguration.
According to the company, other
advantages include a 98% industrial
efﬁciency rating, a compact and rigid
design, fretting-free torque transfer
UTS
ENHANCES
I NT EGRAT ED GEAR
SOF T WARE PACKAGE
Universal Technical Systems released
a new upgrade for its Integrated Gear
Software product line for greater ease
of use.
According to the company’s press
release, a new built-in DXF converter
allows users to bring coordinates from
IGS into a CAD system for 2-D or
3-D use. Other new features include
the addition of the Ticona M15HP
high performance engineering plastic
material and further animation of gear
rotation through the length of the active
proﬁle.
UTS says a new range analysis capability
offers improved “what-if ” analysis in
less time. The new software quickly
generates a table of results to help users
arrive at the optimum design solution
more quickly. The new range analysis
facility is available in 80+ programs in
IGS. 
For more information:
Universal Technical Systems
202 W. State St., Ste. 700
Rockford, IL 61101
Phone: (800) 435-7887
E-mail: [email protected]
Internet: www.uts.com
using a friction locked ﬁt between shaft
and bevel gear, and a lifetime lubrication
guarantee.
Typical applications are angular torque
transfer and torque distribution in
single- or multiple-shaft conﬁgurations
as well as in non-stationary applications
where weight is a consideration. 
For more information:
Neeter Drive
Power Jacks Group
Maconochie Rd., Fraserburgh
Scotland, U.K.
Phone: +(44) 1346-513-131
E-mail: [email protected]
Internet: www.powerjacks.com


Zero-Max’s
Linear
Actuators
CONVERT ROTARY MOTION
INTO PRECISE LINEAR
MOTION
The Roh’lix linear actuators from Zero-
Max convert rotary motion to linear
travel and carry loads at speeds up to
70" per second, depending on size. They
are designed for positioning operations
in different types of machinery and are
an alternative to ball screws.
The actuators are built to handle
thrust rated between 5–200 lbs., and
loads can be attached to the Roh’lix
carrier block using two cap screws. The
product’s thrust capacity is adjustable,
so the system will disengage if the
present thrust is exceeded, providing
overload protection if an obstruction
is encountered.
The linear actuators consist of three
replaceable precision ball bearings at
each end of a two-piece aluminum carrier
block. Mounted at an angle to the drive
axis, the six bearings convert drive shaft
rotation into proportional linear travel.
With a minimum of 90% efﬁciency, the
actuators can normally provide up to
100 million inches of linear travel. The
movable Roh’lix carrier block travels on
a smooth, threadless, hardened RC 58
shaft that requires no lubrication, Zero-
Max says in its press release. 
For more information:
Zero-Max
13200 6th Ave. N.
Plymouth, MN 55441
Phone: (763) 546-4300
E-mail: [email protected]
Internet: www.zero-max.com
6 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006

product news




Alpha Gear’s
Newest
Software

SIMPLIFIES SELECTING
GEAR REDUCERS
The Cymex calculation software from
alpha gear drives Inc. uses a database
of company products and 6,000 motors
from various manufacturers.
According to the company’s press
release, users simply enter their
application data, and the software
will immediately calculate the most
appropriate drive train. Users can
experiment with different load cases,
varying the parameters and testing the
preferred drive systems in detail. The
software then compiles comprehensive
technical documentation.
Beyond the basic Cymex 3.0 Design
Edition package, the Cymex 3.0 Motion
Edition allows users to lay out a complete
drive system with a mouse click. In the
Motion edition, belt, volume, spindle,
turntable and rack-and-pinion drives are
pre-deﬁned as standard applications.
Additionally, arbitrary general load
cases can be computed. Along the drive
system, it is possible to output data at
every one of the six dial gages (torque,
number of revolutions, mass-moment
of inertia, translations, etc.) to optimize
the drive. 
For more information:
alpha gear drives Inc.
1249 Humbracht Circle
Bartlett, IL 60103
Phone: (630) 540-5341
Internet: www.alphagear.com
PCB
Piezotronics’
NEW ROTARY TORQUE
SENSOR SYSTEM ASSESSES
AUTOMOTIVE DRIVELINES
The rotary torque sensor system from
the Force/Torque Division of PCB
Piezotronics is designed for automotive
driveline and power train dynamometers
and other torque measurement
applications requiring a robust torque
transducer.
The Torkdisk features a telemetry
system consisting of an on-board
electronic module that converts torque
signals into a high-speed 16-bit digital
output. According to the company’s
press release, styles are available that use
a non-contact, maintenance-free design
that eliminates the need for replacing
worn brushes, as is the case with
conventional slip-ring type rotating
torque sensors.
Applications include dynamometer
testing of gasoline and diesel engines,
transmissions, transfer cases, differentials
and drive shafts. Additional applications
include torque studies on pumps, fans and
electric motors. Rotary torque sensors
are offered in capacities from 0.35 N-m
to 25.4 kN-m full scale and maximum
speeds to 15,000 rpm. 
For more information:
PCB Piezotronics Inc.
Force/Torque Division
3425 Walden Ave.
Depew, NY 14043
Phone: (888) 684-0004
E-mail: [email protected]
Internet: www.pcb.com
April 2006 Gear Product News 077 April 2006 Gear Product News
product news

Bison Gear
INTRODUCES LINE OF AC
MOTORS
Bison Gear & Engineering introduced
a new line of custom AC motors
manufactured in its St. Charles, IL,
facility.
Motors will be available in the 34 and
49 frame. The 34 frame (3.3") OD will
have a power range of 1/80 hp (10 W)
to 1/10 hp (75 W) with a 1/2" standard
shaft diameter. The 49 frame (4.9") OD
will have a power range of 1/10 hp (75
W) to ¼ hp (185 W) and will have
a 1/2" standard shaft diameter. The
motors will be available as PSC, split
phase, three-phrase and three-phase
inverter style. Winding conﬁgurations
are available as well. The company says
its U.S. manufacturing location allows it
to offer short lead times. 
For more information:
Bison Gear & Engineering
3850 Ohio Ave.
St. Charles, IL 60174
Phone: (630) 377-6777
Internet: www.bisongear.com
8 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
product news

Haas
Automation’s
MACHINING CENTER
UTILIZES IN-LINE, DIRECT
DRIVE SYSTEM
The VF-6SS from Haas Automation
is a high performance vertical
machining center designed for
high volume production and work
necessitating high speed and short
cycle times.
The machining center comes standard
with a 12,000 rpm inline direct-drive
spindle, ultra-fast tool changer and high-
speed rapids. It also is equipped with a
40-taper spindle that uses an inline,
direct-drive system to couple the motor
directly to the spindle. According to the
company’s press release, this yields less
vibration, heat and noise than other drive
systems, providing improved surface
Mitutoyo’s
CMM
INCORPORATES RECENT
TECHNOLOGIES
The Legex 574 CNC coordinate
measuring machine from Mitutoyo
America combines state-of-the-art
design, electronics, computing, sensors
ﬁnishes, extreme thermal stability and
quieter operation. The spindle’s 30-hp
vector dual-drive system provides low-
end torque and the required speed for
high-speed machining operations.
Additional features include a high speed,
24 pocket side-mount tool changer that
swaps tools in 1.6 seconds. To further
reduce cycle and non-machining time,
high pitch ball screws and high torque
servo motors for rapids of 1,200 ipm
on the Y and Z axes and 900 ipm on
the X axis are provided. More standard
features include an automatic chip
auger system, programmable coolant
nozzle, ﬂoppy disk drive, 1 MB of
program memory, Visual Quick Code
programming and a remote jog handle. 
For more information:
Haas Automation
2800 Sturgis Rd.
Oxnard, CA 93030
Phone: (805) 278-1800
Internet: www.HaasCNC.com
and materials to offer improved
performance.
According to the company’s press
release, accuracy of MPE
E
= (0.35 +
L/1000) µm, a measuring range of X:
510 mm, Y: 710 mm and Z: 455 mm
and a worktable loading capacity of 200
kgf make the machine suitable for a
diverse range of applications.
The Legex is driven by MCOSMOS
(Mitutoyo Controlled Open System for
Modular Operation Support) software
with modules supporting numerous
CAD formats while providing in-line
measurement, data feedback and process
management
In addition, the machine uses spheroidal
graphite ductile cast iron for the chassis
and air-damped spring isolators in order
to attenuate vibration. A FEM (Finite
Element Modeling) analysis optimizes
its conﬁguration to ensure geometric
accuracy by minimizing the de-
formations caused by normal machine
operation. Thermally stable compo-
nents and real-time temperature
compensation maintain accuracy when
operating under temperatures from
64.4°–71° F. Available probes include
contacting scanningas well as laser and
vision. 
For more information:
Mitutoyo America Corp.
965 Corporate Blvd.
Aurora, IL 60504
Phone: (630) 978-5385
E-mail: [email protected]
Internet: www.mitutoyo.com

April 2006 Gear Product News 099 April 2006 Gear Product News
product news

Mori Seiki’s
HIGH EFFICIENCY SHAFT
MACHINE ONE-THIRD THE
SIZE OF PREVIOUS MODELS
Mori Seiki released the NZ-S1500 2-
turret shaft lathe for shaft machining.
Workpieces that can be machined are
restricted to those with a maximum
machining diameter of ϕ120 mm and a
standard machining diameter of ϕ60∼20
mm. According to the company’s press
release, the size of this shaft machine
was reduced to one-third of that of
the previous model. A symmetrical
construction in which two turrets are
aligned with the spindle, which is
mounted on the vertical bed, is used.
The machine’s 1,500 mm height allows
for easier chip discharging as well as
great visibility.
Other features include a vertical
protector that prohibits chip
accumulation, three-point support
construction, and a high speed
loader with rotary hand function. 
For more information:
Mori Seiki Co. Ltd.
2-35-16 Meieki, Nakamura-ku
Nagoya City 450-0002
Japan
Internet: www.moriseiki.com
Baldor’s
Motors
OFFER LOW INERTIA
Baldor Electric Co. offers low inertia,
high efﬁciency, high cycle brake motors
with cast aluminum footless frames for
increased thermal dissipation.
According to the company’s press
release, a DC brake with integral rectiﬁer
provides faster action than traditional
spring-set brakes, and the motors
feature a low inertia design best suited

www.comtorgage.com
®
Rugged,
Reliable,
Repeatable
...For 75 Years!
COMTOR SPLINE GAGES
Internal or External Spline Measurement
Made Easy!
Still using micrometers and pins method?
Comtor Spline Gages make pitch diameter
measurement quick, easy and accurate!
Comtorgage Corporation
(since 1928)
Phone: (401) 765-0900 • Fax (401) 765-2846
Pitch
Diameter
Major
Diameter
Minor
Diameter
www.comtorgage.com
®
Rugged,
Reliable,
Repeatable
...For 75 Years!
COMTOR SPLINE GAGES
Internal or External Spline Measurement
Made Easy!
Still using micrometers and pins method?
Comtor Spline Gages make pitch diameter
measurement quick, easy and accurate!
Comtorgage Corporation
(since 1928)
Phone: (401) 765-0900 • Fax (401) 765-2846
Pitch
Diameter
Major
Diameter
Minor
Diameter
Rugged, Reliable, Repeatable
...For 75 Years!
Pitch
Diameter
Major
Diameter
Minor
Diameter
®®®
®
10 Gear Product News April 2006 Gear Product News April 2006
product news

for continuous start/stop applications.
A die cast aluminum frame aids in heat
dissipation. The brake coil is powered
by an integral rectiﬁer connected in
the motor conduit box so it may be
separately connected if the motor is
used with an inverter.
Baldor brakes are available in ½–2
horsepower for applications including
baggage conveyors and any other
applications requiring frequent
stopping.
For more information:
Baldor Electric Co.
5711 R.S. Boreham, Jr. St.
P.O. Box 2400
Fort Smith, AR 72901
Phone: (800) 828-4920
Fax: (479) 648-5792
Internet: www.baldor.com
Parker Bayside
COMBINES SERVO MOTOR
AND HELICAL PLANETARY
GEARHEAD
Each gearmotor in the Stealth line
from Parker Bayside is a brushless servo
motor and a helical planetary gearhead
integrated into a single product.
According to the company’s press
release, the motor magnets are attached
directly to the input gear shaft,
eliminating the extra couplings, shafts
and bearings normally required. The
servo gearmotor simpliﬁes installation
by eliminating potential conﬁguration
and assembly problems associated
with conventional separate motor/gear
packages. Available as both in-line
and right-angle units with operations
for metric/NEMA conﬁgurations and
special output shafts, ﬂanges and/or
windings, the gearmotor can save space.
Units are available with 160 VDC or
300 VDC windings and ratios from 5:1
Alpha Gear
INTRODUCES ECONOMY
LINE OF GEARHEADS
The LP+/LPB+ value line of gearheads
from alpha gear drives Inc. offer
efﬁciency with low torsional backlash
for less demanding applications.
According to the company’s press
release, the gearheads are maintenance-
free for their entire service life due to a
unique lubrication concept.
The LPB+ offers the option of adding
an integrated geared pulley drive system.
The belt pulley eliminates the need for
a right-angle gearbox, couplings and/or
additional bearings.
The company says the gear reducers
achieve a 95% efﬁciency at full load.
The two-stage reducer restricts torsional
backlash to 10 arc-minutes while the
single-stage version operates at less than
eight arc-minutes. 
April 2006 Gear Product News 011 11 April 2006 Gear Product News
product news
to 100:1 for a variety of speed and torque
ranges. Encoders, resolvers and brakes
are offered as standard options without
increasing the overall unit size. 
For more information:
Parker Bayside
5500 Business Park Dr.
Rohnert Park, CA 94928
Phone: (707) 584-7558
Internet: www.parkermotion.com

Send us
your product news! your product news!
Robin Wright,
Assistant Editor
Gear Technology
1425 Lunt Ave.
Elk Grove Village, IL 60007
[email protected]
For more information:
alpha gear drives Inc.
1249 Humbracht Circle
Bartlett, IL 60103
Phone: (630) 540-5341
E-mail: [email protected]
Internet: www.alphagear.com
12 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
product news
Midwest
Motion’s
GEARMOTOR ACCEPTS
BATTERY POWER
United
Grinding’s

NEWEST MACHINE TURNS
AND GRINDS SHAFTS AND
CHUCKED WORKPIECES
The Studer S242 from United Grinding
is designed for the hard turning and
grinding of high-precision applications
for both shaft and chucked workpieces
such as gear shafts, camshafts,
turbocharger shafts and tool holders.
The Model MMP-TM55-12V GP52-
308 gearmotor from Midwest Motion
accepts any 12-volt DC source including
battery power and measures 2.14" in
diameter by 7.75" long and has a keyed
output shaft of 12 mm diameter by 25
mm long.

According to the company’s press release,
easier mounting is possible with four
face mount M5 threaded holes, equally
spaced on a 40 mm diameter bolt circle.
The gearmotor’s output is rated for
35 N-m continuous torque at 15 rpm
and 70 N-m peak. The motor’s design
requires 7.2 amperes at 12 volts DC
to generate its full load output torque.
Optional 24- and 36-volt windings are
available. The design is rated at IP-54
protection level for operation in harsh
environments.
Typical options available include servo
motors with integral optical encoders,
failsafe brakes, analog tachometers and
planetary gearheads with ratios from 3:1
to 450:1 and standard or low backlash
precision gearing.
For more information:
Midwest Motion Products
10761 Ahern Ave. SE
Watertown, MN 55388
Phone: (952) 955-2626
E-mail: [email protected]
Internet: www.midwestmotion.com

April 2006 Gear Product News 013 13 April 2006 Gear Product News April 2006 Gear Product News
product news
The Ultimate Shopping Mall for Power
Transmission Components
powertransmission.com™
• Gears • Bearings • Motors • Speed Reducers
• Sprockets • Actuators
• Linear Motion… and more
New Products 12/20/04 5:19 PM Page 14
According to the company’s press
release, a part can be fully machined
with a single clamping, reducing
machining time, idle time and logistics
costs (ﬁxturing and reﬁxturing from one
machine to another). Modular design
for quick setup and changeover, state-
of-the-art digital control and drive
systems and step-by-step programming
are designed for ﬂexibility. Swing
diameter is 185 mm and between-
centers grinding length is 400 mm, with
an 800 mm version coming late in 2006.
Depending on the application, parts up
to 1,000 mm can be machined, and the
maximum workpiece weight is 25 kg.
A rigid longitudinal slide with two
independently-controlled cross slides
for the tool holders ensure short
travels for combined machining and
the ﬂexible use of numerous tools. The
left cross slide holds the wheel head
while the rotating tool turret with eight
tool positions—with an optional four
driven tools for milling and drilling—
is ﬁtted to the right-hand cross slide.
Highly dynamic axis drives with pre-
tensioned linear guideways and linear
measuring systems for in-process
length positioning, length and diameter
guarantee higher precision.
The Grantitan® S103 mineral inclined-
bed machine base meets machine
accessibility requirements, optimum
chip discharge into the chip conveyor,
effective vibration dampening and high
thermal stability.
For more information:
United Grinding
510 Earl Blvd.
Miamisburg, OH 45342
Phone: (937) 859-1975
Internet: www.grinding.com
Out of ThisWorld Out of ThisWorld
Gear Gear
Out of ThisWorld Out of ThisWorld Out of ThisWorld Out of ThisWorld
Tooling
QUALITY
TECHNOLOGY
PRECISION MANUFACTURING
OPERATIONAL EXPERTISE
The quality and precision of our broaches and gears have won customers worldwide
(and beyond!) – from the smallest gearshop to NASA and the Mars Rover.
Precision manufacturing, modern equipment, advanced technology, and quality control,
balanced with talented craftsmanship, means you get nothing but the very best.
Guaranteed the most rigid shank cutters and the highest quality level disk cutters made.
Products that perform. Why use Broach Masters/Universal Gear? Because your parts matter!
As a complete source for all your tooling and production needs. Broach Masters/
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you and your customers expect. Experience the difference!
P E R F O R M A N C E
Manufacturers of:
Broaches
Spline Broaches
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Form Broaches
Serration
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Shaper Cutters
Disk Shapers
Shank Shapers
Hex and Square Cutters
Special Form Cutters
Inspection
Master Gears
Go–No Go Gages
Posiloc Arbors
“Quick Spline” Software
Made in USA
1605 Industrial Drive
Auburn, CA 95603
Phone (530) 885-1939
Fax (530) 885-8157
Web: www.broachmasters.com
Call 530 885-1939 or visit
www.broachmasters.com
GRINDING NEWS
April 2006 Gear Product News 15 April 2006 Gear Product News April 2006 Gear Product News

Three
Processes,
One Machine:
Hobbing, Worm Milling,
Gear Grinding in the Gear Jet
Promoting flexibility, Lambert-Wahli Ltd. has combined
hobbing, worm milling and gear grinding in one machine,
the Gear Jet, creating two models to cover a range of produc-
tion environments.
The 1600 CNC model was designed for job shops making
various types of gears in low- to high-volume production.
“1600” refers to the number of workpiece spindles, 1, and
maximum workpiece length, 600 mm. The 2100 CNC was
designed for shops dedicated to making a few types of gears
in high-volume production. It has two workpiece spindles
and a maximum workpiece length of 100 mm.
The Gear Jet can hob and grind external spur, helical and
straight bevel gears, as well as external worm wheels. It
can also mill worms. The hob assembly swivels 175°, from
–50° to +125°, which allows the machine to hob and worm
mill in the same enclosure. Also, using electroplated CBN
wheels, the Gear Jet performs both generating grinding and
form grinding. “Mostly it’s generating,” says Stefan Mori,
Lambert-Wahli’s president.
The Swiss company manufactures CNC worm and thread
milling machines as well as CNC and non-CNC hobbers.
The Gear Jet is a recent addition to its offerings, having been
introduced first in Europe in April ’05.
The combination machine manufactures gears with diame-
tral pitches ranging from 8–350. Mori says it can mill worms
with modules ranging from “very fine, very small” to 3. He
adds that the machine can hob gears with two parameters to
DIN 1−2 quality: total composite error and tooth-to-tooth
error. He prefers not to disclose how the Gear Jet hobs such
quality for those parameters, but he says the ability involves
the accuracy of the machine’s electronic gearbox, which he
describes as having no backlash.
Mori adds the Gear Jet’s main advantages include fast
changeover, high rigidity, high torque and an advanced user
interface. He explains: High rigidity contributes to longer
tool life and greater gear accuracy because there’s less vibra-
tion, and high torque allows the Gear Jet to take advantage of
hob rigidity and hob materials such as carbides and powder
metals.
All Gear Jet spindles are direct-driven, except for the worm
milling spindle, which is belt-driven. Maximum speed for
the hob spindle is 15,000 rpm, for the workpiece spindle
9,000 rpm and for the worm milling spindle 10,000 rpm.
The Gear Jet’s maximum feed rate is 48 m per minute.
Both models can be either manually loaded or autoloaded.
When manually loaded, their maximum workpiece diameter
is 160 mm. When autoloaded, it’s 120 mm. The 2100 is
commonly an autoloading machine, though. Its two work-
piece spindles allow it to cut a gear on one spindle while
loading a gear blank on the other. Thus, loading time isn’t
part of the 2100’s cycle time.
Another feature is Lambert-Wahli conversational program-
ming software. However, the Gear Jet is capable of open
programming, so a gear manufacturer can use non-Lambert-
Wahli software for his hobbing, milling and grinding. “With
us, it’s completely open,” Mori says. “There’s no black box.”
The machine has an integrated network card as well, so it can be
connected to a local area network (LAN) computer system. 
For more information:
Lambert-Wahli AG
Industriestrasse 24
CH-2553 Safnern
Switzerland
Phone: +(41) 323-56-0272
Fax: +(41) 323-56-0271
E-mail: [email protected]
Internet: www.lambert-wahli.ch
Pagani, Cima and Samputensili are three
companies that have successfully blended
skill in mechanical engineering with a
passion for speed to help develop the kind
of sports cars little boys (even the grown-
up kind) dream about.
Cima S.p.A. was founded in 1942 to manufacture hobbing
machines. To inspect and test the quality of these machines,
the company also began manufacturing gears as a job shop.
In the 1990s, however, Cima discontinued its production
of hobbing machines to concentrate on and develop gear
manufacturing as its core business. In 2005, the company
realized revenues of 25 million euros with 130 employ-
ees. Cima primarily
sells automotive and
motorcycle gears, but
it also has custom-
ers in aerospace and
other industries that
require high quality
gears up to module
5 with a maximum
outside diameter of
350 mm.
Whether it be proto-
type work and small
batch production or
volumes of around
50,000 parts per gear
drawing, Cima puts
technology at its
customers’ disposal:
the latest-genera-
tion machinery, fully
robotic automatic
production lines and
modern heat treat-
ment equipment.
Among the modern
machines at Cima are
the Samputensili S
375 G and S 400 GT
grinding machines.
These machines are
16 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
GRINDING NEWS
A Passion
for Engineering
and Speed
designed for versatility and accuracy in grinding complex
profiles.
Flexibility is also a key feature of these machines, which may
equip any combination of ceramic or CBN electroplated
worm or profile wheels and, in the case of the S 375 G, may
perform internal or external grinding of spur or helical work-
pieces.
On these machines,
Cima grinds the
gears that are mount-
ed in gearboxes for
the most powerful
engines. Because of
the demands on these
gears, nothing is left to
chance. Strict classes
of tolerance, surface
roughness, lead and
involute crowning, tip
relief and root fillets
are all realized with
Samputensili single-
profile wheels or CBN
or ceramic worm
wheels, depending on
the application. That
attention to detail
means less strain on
mechanical compo-
nents, reduced noise
levels and better per-
formance in the sports
cars.
The collaboration
between Cima and
Pagani began eight
years ago, when the
Example of a
Gear in the Cima Gearbox
M=1.25, Z=42, width 15.5 mm
Machine:
Samputensili S 400 GT
Tool:
Worm wheel 230 mm diameter,
104 mm face width, 5 threads
Cycle:
2 roughing passes with removal of 0.15
mm and 1 finishing pass with removal of
0.04 mm per flank at a speed of 60 m/s
both during roughing and finishing
Cycle time:
1.25 minutes per piece
Wheel dressing is not performed after
each workpiece. The dimensions of the
wheel mean that it is possible to per-
form dressing every 55–60 pieces with
a cycle time of around 5 minutes, which
corresponds to a time per piece of 5
seconds.
Zonda F Technical
Specifications
Engine:
Mercedes Benz 7.3 CC
Max. Power:
hp/rpm 602/6,150 (443 kW)
Speed:
345 km/h
Weight-to-power ratio:
2.04 kg/hp
Gearbox:
Mechanica l 6-speed + reverse
Structure:
Central—carbon-fiber chassis;
Front and Rear—CrMo space
Frames—
carbon fiber
“MD System” bodywork panels

April 2006 Gear Product News 17 April 2006 Gear Product News April 2006 Gear Product News
For Outsourcing
Your Gear
Manufacturing
7606 Freedom Way • Fort Wayne, IN 46818
Tel: (260) 490-3238 • Fax: (260) 490-4093
www.first-gear.com
Visit our website for more info
www.ﬁrst-gear.com
ISO 9001 : 2000 CERTIFIED
From Prototypes
to High Volume
Production
E N G I N E E R I N G & T E C H N O L O G Y
“YOUR FIRST CHOICE”
Expanding Mandrels
.0001” T.I.R. or better
Expansion Range: 1/4” to 7”
Fast & easy loading -
Ideal for:
Gear Inspection
Gear Grinding
Hob Sharpening
Spline Mandrels
Pitch diameter contact
.0002” T.I.R. or better
Inspection or Grinding
PartLocator
Repeatable Parts Location to .005”
Available on most LeCount Mandrels
LeCOUNT, Inc. 180 Dewitt Drive White River Jc. VT 05001 USA
(800) 642-6713 (802) 296-2200 Fax: (802) 296-6843
[email protected] www.lecount.com
Qual i t y Workhol di ng
owner of Pagani, Horacio Pagani, proposed that Cima design
and produce an entire gearbox, including the box, assembly
and setup.
This challenge was accomplished so well that Cima now man-
ufactures around 50 of these six-speed + reverse gearboxes per
year, 15 of which are for the Pagani Zonda F, a technological
torpedo housed in a carbon-fiber shell. The Zonda F was on
display in March at the Geneva Auto Salon in Switzerland. 
For more information:
Cima S.p.A.
Via Cairoli 8
40050 Villanova di Castenaso - BO
Italy
Phone: +(39) 051-603-2511
Fax: +(39) 051-605-3292
E-mail: [email protected]
Internet: www.cimaingranaggi.it
Samputensili
c/o Star SU LLC
5200 Prairie Stone Pkwy., Suite 100
Hoffman Estates, IL 60192
Phone: (847) 649-1450
Fax: (847) 649-0112
E-mail: [email protected]
Internet: www.star-su.com
GRINDING NEWS
18 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006

Tifco Gage and Gear of Livonia, MI, is known for its preci-
sion components serving the gear industry. A wide segment
of the market—from automotive to aerospace—depends on
Tifco’s know-how and highly skilled technicians.
As quality levels have increased worldwide in the auto indus-
try, quality specifications for master gears and setting masters
have increased in precision, making a tough job ever more
difficult.
To keep up with those requirements and provide increased
capacity, Tifco recently took delivery of a Kapp VUS55P gear
grinding machine (Fig. 1).
With the new machine, Tifco has completed its first set of
internal helical gear setting masters certified to a DIN 2
overall geometric quality with a size tolerance of +/– 0.005
mm between balls (Fig. 2).
For the 1.2-module helical master, this equates to an involute
form tolerance of 1.6 µm. Due to a common tendency in the
Tifco Gage
& Gear:
MASTERS OF PRECISION
Bill Miller, Kapp Technologies, and
Tony Tonello, Tifco Gage and Gear
Figure 1 — A Kapp VUS55P gear grinder.
master gear industry, customer specification of the lead toler-
ance was effectively DIN 1 quality! Under AGMA’s 2000-
A88 standard, the quality requirement for lead tolerance was
effectively class 14.
To explain this more clearly, a typical master gear lead toler-
ance band is shown as a “V” shape with a focal point at one
face, effectively creating a tolerance of zero. This does not
lend itself to analytical evaluation and classification, because
a trace with even a small deviation will not pass through the
focal point. This tolerance band was typically used along
with mechanical lead measuring instruments that claimed an
accuracy of 0.0002" (0.005 mm). The trace was smoothed by
natural filtering of the recorder device and the deviation was
compared with the tolerance band subjectively.
Even though computerized lead and involute instruments
have been in use for more than 20 years and ISO and DIN
standards have provided guidance for master gear quality and
application, it is not uncommon to see tolerance bands rather
than quality class or grade specified. This may be viewed as
a reflection of the methods and machinery available to many
companies designing and/or producing the master gears for
industry. (As a note to designers and manufacturers, the new
AGMA 2015 standard is a welcome and modern classifica-
tion reference.)
The quality levels were certified by Tifco with modern CNC
gear measuring equipment without filtering of the traces.
The tolerance bands were created to allow the trace to pass
through (Fig. 3).
The internal helical size-setting masters were produced on
the new VUS55P using Kapp’s CBN plated wheel technol-
ogy (Fig. 4).
Quality and durability requirements demanded a P/M high
speed steel material hardened to 61–64 HRc. Use of CBN
enabled the grinding of the gear teeth into the solid from
through-hardened condition. As with any high quality gear,
the datum must be equally high quality. Pre-heat treating the
material also made it possible to produce the final datum on
the blank with less distortion. Tifco manufactures its own
clamping devices to necessary precision to establish and
maintain the axis of the gear during the entire process.
The VUS55P produces teeth by discontinuous indexing.
That means each tooth form is ground separately. Sometimes
this is referred to as the single index method. This method
requires especially strict control of all variables to achieve the
tooth-to-tooth quality for master gears. Temperature stabil-
ity of machine elements is provided by refrigeration of the
April 2006 Gear Product News 19 April 2006 Gear Product News April 2006 Gear Product News
gri ndi ng news
Figure 2 — Internal gear setting master.
Figure 3 — Lead and proﬁle inspection charts from an internal helical gear setting master.
coolant oil. Stability is enhanced by continuous circulation
of coolant oil across the machine bed, slides and spindles.
Physical location of the machine in a central area away from
drafts and doors aids in achieving best results.
The VUS55P is equipped with an integral dressing device
mounted directly on the tailstock slide so it is always aligned
and ready for use for either external or internal gear jobs.
The dressing software enables virtually any special form or
gear modification. The software allows the special forms
to be entered point by point or via downloading externally
generated coordinates. The measuring probe and software
enable the machine to iterate towards a perfect solution
automatically. The iterative approach is called “GMG” or
grind-measure-grind. This compensates for deviations due
to dresser shape and other variable conditions at the moment
20 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
Kapp provides a high technology system for reliable setup
and production times on all types of gears, splines and special
forms to gage quality.
Gages are what frequently comes to mind with Tifco.
However, the “Gear” part of the name has become a big-
ger business, in fact. Naturally, the gears produced by Tifco
are specialty gears beyond what can be routinely produced
at commercial gear shops. One such critical application for
Tifco customers is pump gears made from a CPM10V mate-
rial (Fig. 6).
The basic gear data is 13 teeth, 4.7 NDP and 30° NPA. This
poses a unique challenge for CBN grinding wheels. The
material has an extreme low machinability, but it has been
ground for years on Kapp machines successfully with CBN
plated wheels. These gears introduce several other challenges
for gear grinding. The quality required is DIN 2 for profile
form (ff ) and DIN 3 for total profile (F). Achieving the high
geometric quality level is complicated by the fact that one
flank of the pump gear is relieved along the entire length
except for a 10 mm band that requires a precise involute
form. The opposite flank requires the precise involute form
over the entire tooth length. The consequence is a non-sym-
metrical grinding force which can lead to unwanted devia-
tions where the forces change (Fig. 7).
The 16 micro-inch R
a
surface finish specification demands
aa
a fine-grit abrasive and risk of influence from high hydrody-
gri ndi ng news
Figure 4 — Internal grinding setup on a Kapp VUS55P.
of grinding and is a valuable aid to shorten setup times. The
Kapp machine is designed with measurement in mind. All
position measuring scales are of resolutions typical of CMM
equipment (0.0001 mm).
Dressable wheels come in nearly infinite specifications to
suit any work material, and the master gear is no exception.
The advantage of dressable wheels for rapid setup in this
case, however, was offset by a high dressing frequency and a
process with unnecessary extra variables and resultant lesser
quality. CBN wheels were optimally designed for rough
and finish grinding to eliminate the dressing variables. This
resulted in a very reliable quality on the first piece. A size-set-
ting master has an additional degree of difficulty because the
size must be controlled so closely. The additional advantage
of CBN in this case was the elimination of wheel wear in the
final grinding pass. Even though Tifco has applications like
the setting masters, which are ideal for CBN wheels, Kapp’s
optional dressable wheels allow the same machine to be used
for grinding internal or external prototype gears and small lot
applications (Fig. 5).
With the Kapp software for gear measurement, the setup
time required to achieve the first good piece is shortened
considerably. The Kapp dressing and measuring program
enables involute modifications of nearly any type, including
tooth twist (bias) of the flank form along the tooth length.
Tifco has long specialized in the form grinding process
required for precise involute control over master gears. Now
www. James- Engi neeri ng. com
4732 Pearl Street, Boulder, CO 80301
Ph. (303) 444-6787 Fax (303) 444-6561
4 Deburring Models!
462 Bench top
562 Enclosure with dust control
762 Large gear enclosure (40" dia.)
962 Fully automatic system (3,500 parts per day)
We now offer
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Factory Direct Sales
462 562
Gear Deburring
MIDWEST GEAR
& TOOL, INC.
15700 Common Rd.
Roseville, MI 48066
CONTACT:
CRAIG D. ROSS
(586) 779-1300
FAX (586) 779-6790 [email protected] [email protected]
April 2006 Gear Product News 21 April 2006 Gear Product News April 2006 Gear Product News
gri ndi ng news
namic forces while grinding. These challenges are met with
an HSS grinding wheel body and a wheel spindle with high
stiffness. The workholding secures the pump gear with posi-
tive drivers. A special grinding process technology is applied
on the Kapp grinder to optimize wheel peripheral speed, feed
rate, stock removal and coolant flow, to ensure that the wheel
cuts evenly with high hydrodynamic forces. Grinding of
one flank at a time is sometimes employed in cases like this.
However, where possible, this is avoided due to the cycle time
penalty. Again, the temperature variable exists not only for
the machine elements but for the workpiece itself. A balance
is achieved between grinding speed and feed to minimize
temperature increase of the workpiece.
Figure 5 — External grinding setup on a Kapp VUS55P.
Figure 6 — Typical aerospace pump gears.
Figure 7 — Aerospace pump gears with asymmetrical ﬂank relief.
22 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
gri ndi ng news
Form grinding any gear with only 13 teeth also requires
precise axis positioning and centering of the wheel to avoid
deviation of involute angle. The center line of the CBN
wheel is established during the replating process. Even still,
very slight temperature influences to the work area can ren-
der a deviation beyond acceptable limits. The Kapp GMG
technology is useful in this case to correct the deviation by
automatically finding the true center position of the wheel.
In the end, Tifco was able to achieve a total cycle time which
is many times faster than previous methods. Reliability of the
process allows consistent production rates even under these
extraordinarily challenging conditions. This is most impor-
tant to enable volume increases in production.
Tifco is prepared for the future, where high performance
components are made from increasingly advanced P/M
materials. Tifco is equipped with various grinding arm sizes
to cover most possible geometries of internal helical gears.
The small grinding arm uses wheels with diameters of
50–60 mm, and the larger arm can use up to 130 mm diam-
eter wheels. Any type of dressable abrasive wheels may be
used on the Kapp grinder, including 3SG, 5SG, aluminum
oxide and CBN. Dressable grinding wheel bond hardness,
grit density, size and hardness are all variables of the grind-
ing process. The learning curve for Tifco is shortened due
to its long experience with single index form grinding via
dressable wheels. Still, the availability of the CBN plated
tool from Kapp provides huge versatility and allows selec-
tion of the best of both technologies on one machine. 
For more information:
Kapp Technologies
2870 Wilderness Place
Boulder, CO 80301
Phone: (303) 447-1130
Fax: (303) 447-1131
E-mail: [email protected]
Internet: www.kapp-usa.com
Tifco Gage & Gear
33067 Industrial Rd.
Livonia, MI 48150
Phone: (734) 525-8000
Fax: (734) 525-8400
E-mail: [email protected]
Internet: www.tifcogagegear.com
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24 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
April 2006 Gear Product News 25 April 2006 Gear Product News April 2006 Gear Product News
T
he need to increase operational efficiencies is a daily
requirement in the highly competitive global automo-
tive manufacturing environment. This is clearly seen
at the transmission development and manufacturing
facilities of Getrag Ford Transmissions in Köln, Germany, and
Halewood, England. At those factories, high volume production
is required, but so is flexibility.
Originally, the Köln plant was set up as a high-volume, fully
automated manufacturer. However, the increasing size of the
Getrag Ford customer base—Ford, Jaguar, Mazda and Volvo,
to name few—along with ever-changing volumes and product
mixes between five- and six-speed manual transmissions as well
as automatic transmissions create the need for greater flexibility.
Today, Getrag Ford’s plants in Halewood and Köln are set up in
manufacturing cells to make transmissions in smaller volumes—
approximately 50,000 units per year. But getting to that point
required changes in philosophy as well as machining processes to
allow Getrag Ford to manufacture a spectrum of parts with up to
four part changeovers daily.
A New Direction for
Flexible Shop Floor Manufacturing
Because flexible manufacturing presented a new challenge to
Getrag Ford, the company was willing to try new concepts. After
extensive studies of the possible manufacturing methods, the
specialists at Getrag Ford decided to test and implement a new
combination of shop floor processes—modern CNC gear shap-
ing and gear honing—to replace the processes that had been in
place—gear hobbing and gear shaving. In order to test this new
strategy, the concept was implemented in both the Köln and
Halewood facilities.
gear tooth honing:
Economical
and Flexible
As it turned out, one gear shaping machine and one Präwema
precision gear honing machine were sufficient to produce the 14
different gears of the MT82 six-speed transmission, a manual
transmission used on Ford rear-wheel-drive light trucks and
minivans, such as the Ford Transit vehicles.
The gear shaping and honing machines allowed similar flex-
ibility in Köln, where they are being used to manufacture the
MMT6 six-speed manual transmission for front-wheel-drive
vehicles such as the Ford Mondeo.
According to Dr.-Eng. Christoph Schulte, leader of the gear
research department at Getrag Ford, “This is revolutionary.”
“The technology provides the quietest gears possible, excellent
surface finish with increased residual stresses, making the gears
much more resistant to pitting and premature failure,” says Scott
Knoy, vice president of sales for American Wera, which repre-
sents Präwema in the United States.
Knoy adds that the cycle times and costs of gear honing
are equivalent to gear shaving, but honing produces a higher
quality gear.
Choosing this course of action was a relatively high-risk proposi-
tion for Getrag Ford, considering the tenacity of today’s global
competition. In the current market, the basic prerequisite for a
partner is 24-hour service with guaranteed product reliability.
Despite those demands, there have been no significant problems
since the installation of these processes in January 2004, accord-
ing to Schulte.
continued
26 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
In fact, the new setup has piqued the interest of many potential
customers. According to a Getrag Ford spokesman, the combi-
nation of shaping and gear honing enables the company to have
a tighter control on delivery and allows it to be more competitive
in the world market, even with a product being manufactured in
high-cost countries like England and Germany.
A Direct Comparison Proves the Point
Schulte says he is generally reserved in the comparison of differ-
ent gear production processes. All relevant technical criteria have
to be taken into consideration. Those criteria include the amount
of material removed, production quality and manufacturing-
induced deviations, tooling costs, personnel costs, machining
costs and scrap costs.
Keeping all that in mind, Schulte says, “The modern gear shap-
ing and honing processes—carried out as individual stepped
processes—are comparable on the cost side to the costs of con-
ventional shaping [alone]. Chiefly, the high precision Präwema
honing process makes for a very logical compromise between
quality and cost. The Präwema honing machines’ remarkably
high process stability and robustness of the machine construction
provide a convincing argument for this case.”
April 2006 Gear Product News 27 April 2006 Gear Product News April 2006 Gear Product News
Combined with the improvements mentioned above, this has
allowed Getrag Ford’s average cycle time to be reduced from 60
seconds to 30 seconds during the time period from 1999–2005.
Despite these improvements, the expectations of engineers and
management at Getrag Ford Transmissions are high, and they
are convinced that there are many more possibilities for process
optimization. 
For more information:
Präwema Honing Machines
c/o American Wera Inc.
4630 Freedom Dr.
Ann Arbor, MI 48108
Phone: (734) 973-7800
Fax: (734) 973-3053
E-mail: [email protected]
Internet: www.american-wera.com
Tyrolit Gear Honing Tools
c/o Koepfer America LLC
635 Schneider Dr.
South Elgin, IL 60177
Phone: (847) 931-4121
Fax: (847) 931-4192
E-mail: [email protected]
Internet: www.koepferamerica.com
A German-language version of this article appeared in the
March 2005 issue of the magazine Werkstatt und Betrieb. It has
been translated and expanded here for Gear Product News.
Getrag Ford sees high precision honing as the most economical
hard gear finishing process available at this time, as evidenced
by the increasing number of parts being honed at Köln and
Halewood.
One of the keys to achieving high quality with honed gear teeth
is the quality of the incoming part. At Getrag Ford, flank-form
modifications generated by the gear shaping process are con-
trolled by statistical process control (SPC).
Josef Siebler, Präwema sales director, sees the advantage in the
details: “The high quality of the incoming gears relative to the
bore and the faces are essential and can improve the overall qual-
ity that can be achieved by the Präwema honing process.”
Currently, Getrag Ford is working to improve even further the
surface finish of the gear flanks in the shaping process. As they
do so, Getrag Ford engineers expect shorter cycle times for the
Präwema honing machines and a marked decrease in tooling
costs, making the company even more competitive, Siebler says.
Training and Process Efficiency are Key
Since honing is a completely new manufacturing strategy for
Getrag Ford, the company requires even greater expertise out
of its workforce. “Our new manufacturing strategy will demand
more qualified personnel to obtain optimal process capacity,”
Schulte says. “It is necessary in the manufacturing planning, for
the plants in England and Germany, to place a greater emphasis
on the training of the workforce. In addition to process training,
we have identified plant layout, logistics and automation plan-
ning as areas where future training needs to take place.”
Another area where training and expertise come into play is
automation. The optimization of part-to-part changeover times
and standardization of tooling take high priority in automation.
The workforce in Köln has amazed the engineers at Präwema
with a number of good ideas for process improvement, Siebler
says. Examples of this ingenuity include the error-proofing of
incoming parts using a sheet metal profile gage and combin-
ing the diamond dressing gear and diamond dressing roll into
a single tool.
The transmission specialists in Köln have relied on support
from Präwema and its tooling partner, Tyrolit-Reineke, to
continue improving the productivity of this new manufactur-
ing concept. With the help of these experts, Getrag Ford has
been able to shorten the average process times for honing parts.
Improvements made to the original system have included a faster
Indramat CNC controller, the use of linear motors in the X, C,
B and Z axes and software designed to identify the shortest pos-
sible axial travel distances.
Furthermore, Tyrolit-Reineke has developed a dressable ceramic
tool for the Präwema honing machine that makes it possible
to shorten the cycle time per part an additional 8–11 seconds.
28 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
G
Honing:
The Secrets
of Hole Finishing
ear manufacturers spend a lot
of time worrying about gear
teeth. It’s their specialty, after
all. They have specialized
equipment and technical expertise that
aren’t found at just any manufacturer.
But an often-overlooked, yet incredibly
important, part of the manufacturing
process is the quality of the gear bore.
Without proper bore size, cylindricity and
surface finish, all a gear manufacturer’s
hard work on the gear teeth could go
to waste, especially in parts that use the
inner diameter for a bearing surface or
that require close tolerances for shaft or
bushing fits.
That’s why many gear manufacturers use
honing to finish the bores. The advan-
tages of honing include proper function-
ing of bearings, increased life of the gears
or bearings, increased accuracy of the
powertrain and lower noise levels.
What’s Honing?
Honing is an abrasive process that uses a
rotating tool to machine metal from the
interior diameter of a bore or cylinder.
One of the most common uses of honing
is bore sizing and finishing the cylinders
of automotive engine blocks. But any
application that requires precise control
over the size and shape of an inside diam-
eter could be a candidate for honing.
Traditional honing tools use abrasive
stones mounted in an expanding mandrel.
As the tool rotates, the tool—or in some
cases the part—reciprocates rapidly. In
modern machines, the expansion of the
mandrel is CNC-controlled to ensure
precise honing of the bore.
Traditional honing stones use bonded
abrasives, from aluminum oxide up to C
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April 2006 Gear Product News 29 April 2006 Gear Product News April 2006 Gear Product News
Honing:
The Secrets
of Hole Finishing
CBN or diamond, depending on the
application. Because the bonded matrix
wears down during production, new, fresh
abrasive grits are constantly exposed. Also,
because the stones are on an expanding
mandrel, the size of the bore is automati-
cally adjusted.
Traditional honing has the largest range
of applications, says Rich Moellenberg,
custom products manager with Sunnen
Products Co. “It is compatible with almost
all part materials. If the surface finish of
the bore is important to the performance
of the gear, such as a transmission pinion
gear, the manufacturer will choose tradi-
tional honing.”
Traditional honing is performed on either
vertical or horizontal machines designed
for rapid reciprocation of either the tool
or the part. Generally, a single, rotating
spindle carries the expanding mandrel
with the abrasive stones.
Electroplated tools offer some alternatives
for honing, especially in higher volume
applications. For example, the patented
Krossgrinding® system from Sunnen
applies diamond-plated abrasive to an
expanding mandrel. These tools are “typi-
cally the most accurate honing tool, but
do not necessarily offer the lowest perish-
able cost per bore,” says Moellenberg.
Krossgrinding tools are expanded under
CNC control, and bore diameter size can
be changed in 0.0001 mm increments,
with repeatability within 0.0001 mm,
Moellenberg says.
Both conventional honing and
Krossgrinding tools are capable of remov-
ing relatively large amounts of stock. Also,
they produce a “crosshatch” surface finish
pattern, which helps hold lubrication.
This crosshatch pattern is also essential if
the bore of the gear acts as an outer bear-
ing race, Moellenberg says.
Another type of electroplated honing
tool is designed for sizing or finishing the
bore in a single pass or stroke. Instead of
being mounted on an expanding man-
drel, the tool itself is a solid substrate,
with the abrasive material (usually dia-
mond or CBN) plated directly onto the
tool. Examples include the Single-Pass
tools from Engis and the Single-Stroke
Honing tools from Sunnen.
These tools are used for removing only a
small amount of material, but productivity
rates are extremely high. When the appli-
cation is right, this is the least expensive
method of honing, with per-part costs of
about $0.01.
The single-pass honing process provides a
number of advantages, says Bob Marvin,
Engis product manager.
The first advantage of single-pass tools is
good precision. “In fact, this process can
hold quality to better than a 2 Cpk in
production,” Marvin says.
Also, the single-pass process offers high
productivity without complicated tooling.
With this type of tooling and machine,
productivity can be as high as 600 parts
per hour, Marvin says. Although conven-
tional honing can achieve similar high
production rates, it requires parts like
gears to be stacked in order to do so. This
requires complicated fixturing and can
result in a loss of accuracy.
Finally, the cost of $0.01 per part is what
is most attractive, Marvin says. “This is at
least half the cost of conventional honing
and much less than grinding. The long
tool life also promotes less downtime and
overall lower cost per piece.”
Moellenberg agrees that single-stroke
tooling has its advantages. However, he
points out that the process has a more
narrow range of applications, compared
to traditional honing. It is difficult to
use plated diamond abrasive tools with
materials that typically develop a “long
chip” when machined. Some materials
also react with the nickel plating that
holds the diamond abrasive to the honing
tool. Examples include 300 series stainless
steels or 8620 steel. With those materi-
als, the honing chips tend to stick to the
nickel, embedding in the part and caus-
ing galling. However, if the application
is right, Moellenberg says, it’s the least
expensive method of honing for both the
perishable tooling cost and the machine
investment.
continued
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30 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
In some cases, the single-stroke tools
can be used in conjunction with a hon-
ing machine that incorporates a rotary
index table and multiple spindles, so that
multiple tools with increasing diameters
can be used in succession. This allows the
manufacturer to increase the amount of
stock removed without increasing cycle
time.
Where Does Honing Fit In?
In most cases, honing is a finishing pro-
cess, used after heat treating to put the
final size on an inside diameter. Generally,
Moellenberg says, the bore is honed, the
teeth are cut, the part is heat treated, and
then the part is finish honed to remove
any heat treat distortion.
Many gear parts have interior features,
such as internal splines, keyways or holes
for set screws. Although these interrupted
cuts often are more demanding and cause
problems for many abrasive processes,
they can be honed with the right tooling.
“These types of gear bores are typically
honed for bore diameter and bore geom-
etry tolerance,” Moellenberg says.
Engis has one customer that uses the
single-pass process to hone the inside
diameter of a component with an internal
spline. This creates a good locating sur-
face for a subsequent gear tooth grinding
operation, Marvin says.
“Internal recesses or splines can have
a negative effect on processes such as
grinding, hard turning and conventional
honing,” Marvin says. “This is due to the
cutting insert or honing stone hitting the
edges of the cutout during the cutting.
The single-pass process does not have this
problem because the tool is self-centering
in the bore and has full contact with the
bore around the periphery of the tool.”
No matter the application, though, both
Marvin and Moellenberg agree that hon-
ing is a crucial step in manufacturing
precision gears. 
For more information:
Engis Corp.
105 W. Hintz Road
Wheeling, IL 60090
Phone: (847) 808-9400
Fax: (847) 808-9430
E-mail: [email protected]
Internet: www.engis.com
Sunnen Products Corp.
7910 Manchester Avenue
St. Louis, MO 63143
Phone: (314) 781-2100
Fax: (314) 781-2268
E-mail: [email protected]
Internet: www.sunnen.com
this means it’s done after the gear teeth
are cut.
But in some cases—particularly for high-
er precision gears—honing is performed
before the teeth are cut. “The accurate
bore in the gear blank makes the gear
blank very accurately fixtured in the gear
hobbing machine,” says Moellenberg.
“This produces superior gear teeth to the
bore centerline tolerance.”
Often with such high precision gears,
C
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VISIT
TODAY!
��
www.geartechnology.com
www.geartechnology.com
The Gear Industry Home Page™
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32 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
t he bas i cs of Ha r mo n i c

April 2006 Gear Product News 33 April 2006 Gear Product News April 2006 Gear Product News
H
armonic drives were invent-
ed in the late 1950s and
have been a major part of
the motion control industry
since then. In that time, several innova-
tions, improvements and adaptations have
been made, allowing harmonic drives to
become a primary choice for applications
requiring precise positional accuracy and
repeatability.
They are now available as fully housed
gearheads, actuators complete with motor
and encoder, or in custom configurations
with special materials, greases or cus-
tomer-specific designs that allow for easy
adaptability.
Since they were invented, one aspect of
harmonic drive gearing has remained
constant: their principle of operation.
Most people in industry are familiar with
the term harmonic drive and have either
heard about them or seen them in pass-
ing, but few understand how they work
or why they’re capable of high ratios,
zero backlash, and high torque-to-weight
ratios.
Harmonic Drive Gearing—Do
You Really Know How it Works?
The operating principle of harmonic drive
gearing is one of the most misunderstood
of all gearing technologies.
The mechanism is comprised of three
components: wave generator, flexspline,
and circular spline (Fig. 1).
Wave Generator. The wave generator is
actually an assembly of a bearing and a
steel disk called a wave generator plug.
The outer surface of the wave generator
plug has an elliptical shape that is careful-
ly machined to a precise specification. A
specially designed ball bearing is pressed
around this bearing plug, causing the
Anthony Lauletta
bearing to conform to the same elliptical
shape as the wave generator plug.
The wave generator is typically used as
the input member, usually attached to a
servo motor.
Flexspline. The flexspline is a thin-walled
steel cup with teeth machined into the
outer surface near the open end of the
cup. The large diameter of the cup allows
it be radially compliant, yet remain tor-
sionally stiff.
The cup has a rigid boss at one end
to provide a rugged mounting surface.
During assembly, the wave generator is
inserted inside the flexspline in the same
axial location as the flexspline teeth. The
flexspline wall near the brim of the cup
conforms to the same elliptical shape as
the bearing. Effectively, the flexspline
now has an elliptical gear pitch diameter
on its outer surface.
The flexspline is usually the output mem-
ber of the mechanism.
Important: Although the steel flexspline
flexes during normal operation, there
is no concern about fatigue failure. The
stresses developed are far below the
endurance limit of the material. Thus, the
flexspline will achieve infinite life when
used according to catalog ratings. This is
explained better in Figure 2.
Circular Spline. The circular spline is a
rigid circular steel ring with teeth on the
inside diameter. The circular spline is
usually attached to the housing and does
not rotate.
The teeth of the circular spline mesh
with the teeth of the flexspline. The
tooth pattern of the flexspline (which is
now elliptical—as a result of conforming
t he bas i cs of Ha r mo n i c

Fig. 1—Components of harmonic drive
gearing.
continued
Dr i v e Ge a r i n g
Circular Spline
34 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
Fig. 3—Tooth engagement of harmonic drive gearing.
Fig. 2—Harmonic drive gearing is designed for infinite life.
Stress
# Cycles
Endurance Limit
of Flexspline
Flexspline Stress @ Repeated Peak Torque
10
6
Safety Factor
10
7
10
8
10
9
to the wave generator’s elliptical shape)
engages the tooth profile of the circu-
lar spline along the major axis of the
ellipse. This engagement is like an ellipse
inscribed concentrically within a circle.
Mathematically, an inscribed ellipse will
contact a circle at two points. However,
the gear teeth have a finite height. So
there are actually two regions (instead of
two points) of tooth engagement.
In fact, up to 30% of the teeth are engaged
at all times on the major axis. The pres-
sure angle of the gear teeth transforms
the output torque’s tangential force into a
radial force acting on the wave generator
bearing. The teeth of the flexspline and
circular spline are engaged near the major
axis of the ellipse, and disengaged at the
minor axis of the ellipse (Fig. 3).
Here’s the Trick...
The flexspline has two fewer teeth than
the circular spline. So every time the
wave generator rotates one revolution, the
flexspline and circular spline shift by two
teeth. The gear ratio is calculated by
# Flexspline Teeth / (# Flexspline Teeth
– # Circular Spline Teeth)
Since the flexspline has two fewer teeth
than the circular spline, the term (#
Flexspline Teeth – # Circular Spline
Teeth) = –2. For example, if the flexspline
has 200 teeth, the circular spline has 202
teeth. The gear ratio will be calculated as
200/(200–202) = –100. The negative sign
indicates that the input and output rotate
in opposite directions.
Principle of Operation
As the wave generator is rotated by
the primary power source, it imparts a
April 2006 Gear Product News 35 April 2006 Gear Product News April 2006 Gear Product News
Fig. 4—Normally input and output are in
opposite directions.
Fig. 5—A —— variety of configurations are possible. AA
continued
continuously moving elliptical form or
wave-like motion to the flexspline. This
causes the meshing of the external teeth
of the flexspline with the internal teeth of
the circular spline at their two equidistant
points of engagement. This meshing pro-
gresses in a continuous rolling fashion. It
also allows for a full tooth disengagement
at the two points along the minor axis of
the wave generator.
Since the flexspline has two fewer teeth
than the circular spline and because full
tooth disengagement is made possible by
the elliptical shape of the wave generator,
each complete revolution of the wave gen-
erator causes a two-tooth displacement of
the flexspline in relation to the circular
spline. This displacement is always in the
opposite direction of the rotation of the
wave generator (Fig. 4).
For example, if the wave generator is
rotating in a clockwise direction, the two-
tooth per revolution displacement of the
flexspline will be in a counterclockwise
direction, and vice-versa. In this way, a
basic three-element harmonic drive com-
ponent set is capable of functioning as a
speed reducer. Input from a main power
source through the wave generator is at a
high speed, but the two-tooth per revolu-
tion displacement causes the flexspline to
rotate at a considerably slower speed than
the wave generator.
36 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
The reduction ratio which results can be
calculated by dividing the number of teeth
on the flexspline by two. For example, if a
fixed circular spline has 202 teeth and an
output flexspline has 200 teeth, the ratio
would be 200/(200–202) = –100:1*
*The negative sign indicates that the
input and output are turning in opposite
directions.
Other Configurations
In addition to acting as a speed reducer,
a wide variety of configurations can be
achieved with harmonic drive gearing
by changing which element (among the
wave generator, circular spline and flex-
spline) acts as the fixed element, input
element and output element (Fig. 5).
Advantages
The advantages of harmonic drive gearing
over other, more conventional gear trains
are apparent. A simple three-element
construction combined with the unique
harmonic drive principle puts extremely
high reduction ratio capabilities into a
very compact and lightweight package.
This remarkable union of simplicity of
construction with an operating principle
that is unique, also enables backlash to be
held to a minimum.
Zero Backlash. The unique design and
operating principle yield some very con-
venient benefits. The tooth engagement
motion (kinematics) of the harmonic
drive gear is very different than that
of planetary or spur gearing. The teeth
engage in a manner that allows up to 30%
of the teeth to be engaged at all times
(60 teeth engaged for a 100:1 gear ratio).
This contrasts with maybe six teeth for a
planetary gear set, and one or two teeth
for a spur gear set.
In addition, the unique kinematics allow
the teeth of a harmonic drive gear to
be engaged on both sides of the tooth
flank. Since backlash is defined as the dif-
ference between the tooth space and tooth
width, this difference is zero for harmonic
drive gearing.
Consistent Performance. As part of the
design, the gear teeth of the flexspline
are preloaded against those of the circular
spline at the major axis of the ellipse.
They are preloaded such that the stresses
are well below the material’s endurance
limit. This has an important benefit.
In conventional gearing, wear results in
an increase in backlash over time. In
harmonic drive gearing, as the gear teeth
wear, the elastic radial deformation acts
like a very stiff spring to compensate
for space between the teeth that would
otherwise cause an increase in backlash.
This allows the performance to remain
constant over the life of the gear.
High Positional Accuracy. The combination
of harmonic drive gearing principle and
manufacturing technology allows posi-
tional accuracy of 30 arc-seconds (0.008°).
All three gearing components (wave gen-
erator, flexspline and circular spline) are
held concentric at all times. In addition,
the tooth height, pitch circle and toler-
ances are controlled to millionths of an
inch. These factors, when combined with
the 30% tooth engagement, allow for
sustained accuracy far better than other
gearing technologies.
High Torque-to-Weight Ratio. Harmonic
drive gearing offers higher torque-to-
weight and torque-to-volume ratios than
other gearing technologies. The light-
weight construction and single-stage gear
ratios of up to 160:1 allow the gears to
be used in applications requiring mini-
mum weight or volume. Small motors can
exploit the large mechanical advantage
of a 160:1 gear ratio to create a compact,
lightweight and low-cost package.
Affordable Precision. Harmonic drive gear-
ing offers many performance advantages
as compared to conventional gearing
technologies. Yet, its simple and elegant
design allows manufacturing costs to be
roughly equal to that of other precision
motion control technologies. This pro-
vides an attractive cost/benefit proposition
for most motion control applications. 
Anthony Lauletta is manager of
marketing communications with
Harmonic Drive LLC. On Jan.
1, Harmonic Drive Technolo-
gies/Nabtesco of Peabody, MA,
and HD Systems of Hauppauge,
NY, merged to form a new joint
venture, Harmonic Drive LLC.
Harmonic Drive remains com-
mitted to providing the highest
quality harmonic drive gearing
and motion control products
combined with world class cus-
tomer service and support. The
new company will employ over 90
people and be headquartered in
Peabody, MA.
For more information:
Harmonic Drive
247 Lynnfield St.
Peabody, MA 01960-4904
Phone: (978) 532-1800
E-mail: [email protected]
Internet: www.harmonic-drive.com
Immediate Opportunities
in Challenging Aerospace Careers.
•
•
•
• •
• •
Take your career to a whole new level, contact us at
860.649.0000 Ext. 226 or e-Mail to [email protected]
TEAM
APACHE
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America’s Military.
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JOIN US!
or much of this century, a lot of
people have owed their liveli-
hoods to Dr. Max Maag.
After years of development, the Maag
Gear Wheel Co. shipped the first of
many spindle-type gear shapers in 1958.
The Maag design represents a more
practical alternative to hobbing for
manufacturing many types and styles of
large gears. In fact, even today, there are
38 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
F
coarse-pitch, large diameter and nar-
row-gap double helical gears that can
only be manufactured on a Maag-style
machine.
Because of the machine’s precision
capabilities, versatility and production
efficiency, many manufacturers have
found it important to protect their
investments and keep their Maag gear
shapers in tip-top condition—especially
Upgrade
YOUR MAAG GEAR SHAPER
CONTROL SYSTEM SUCCESSFULLY
since the machines are no longer made.
By the time the last new Maag gear
shaper was installed in 1990, the control
technology had changed dramatically.
Also, the robust nature of the Maag
gear machines that once captivated gear
makers eventually became their curse,
as the mechanical components greatly
outlived the electrical controls. Retrofit
became a part of the gear maker’s
vocabulary as a path to continued pro-
ductivity in the future.
A full CNC solution involves install-
ing synchronized servo motors on the
table rotation, table translation and
cutter box motions and removing all
the unnecessary equipment formerly
associated with these motions. The
significant roadblocks one faces going
down the full CNC path include the
natural tendency not to disturb a func-
tioning system and the ability to find a
control system integrator possessing the
intimate knowledge of the inner work-
ings of the Maag gear shaping process.
There are a number of technological
reasons for choosing a full CNC retro-
fit; however, it can be difficult to make
a justifiable business case to support
this decision. During the justification
process, someone always points out that
the Maag will not run any faster after
a retrofit. Those who attempt to make
it run faster, often end up burning
the tooling out faster, which wipes out
savings realized by the increased speed.
In addition, the savings in reducing the
setup time that a CNC solution would
Kenn Anderson
April 2006 Gear Product News 39 April 2006 Gear Product News April 2006 Gear Product News
bring become insignificant when one
considers the ratio of setup time to run
time. Without the prospect of increased
production or significant setup time
reduction, Maag projects are not usually
high on the appropriations list.
But you don’t have to do a full CNC
retrofit. A number of less expensive
retrofit options exist, from a complete
control system upgrade to an indi-
vidual ram drive replacement. Since
1992, Nova personnel have retrofitted
two SH-250s with new control systems,
reusing only the original drive motor,
and one SH-250 with a new control
system and a new drive motor. Nova
has also integrated new drive control-
lers into two SH-450s and one SH-
250/300, each time replacing energy-
hogging motor-generator sets. In every
retrofit case, whether a complete or
partial upgrade was installed, the Maag
shapers either met or exceeded the
production rates of the machines prior
to the start of the projects.
Maag gear makers usually struggle to
justify making improvements to their
shapers, but there are good reasons
why upgrades make sense. Replacing
outdated motor-generator sets provides
a continuous payback due to reduced
energy consumption. Another reason
might be avoiding downtime spent
trying to troubleshoot a relay logic
control system. A major reason to con-
sider an upgrade would be the impend-
ing demise of the ram drive motor or
motor-generator set. Normally, the cut-
ter box motion should be steady with a
smooth turnaround. If there is any jerk-
iness in this motion, it might indicate a
developing problem with the ram drive
system. An emergency full overtime
repair of these components can be very
costly both in terms of direct expen-
ditures and loss of planned produc-
tion time. Funds might be better spent
towards updating equipment on a pre-
planned schedule. Downtime waiting
for the arrival of specially manufactured
or repaired parts can support the case.
A much-overlooked opportunity to
retrofit a Maag is when it is moved,
since the machine is down and usually
rewired anyway.
Another viable business case could be
made for an upgrade when gear shapers
might be underpowered. This condition
would exist when a shaper originally
built to finish previously gashed blanks
was now being used to rough cut. In
that case, increased throughput could
be realized with a power upgrade. In the
late 1990s, the power of these machines
could be increased by replacing the 32
kW DC ram motor with a 70 kW mod-
ern flux vector AC motor. Even though
this combination produces about 15%
less torque than an original 70 kW
Maag DC motor (commonly used on
roughing machines), there still is a
significant improvement over a 32 kW
motor. Today, new motor technologies
can offer solutions to overcome the
shortcomings of the flux vector motor.
The control system of a Maag shaper
consists of an electronic control unit
40 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
and a relay logic section. Since the
initial introduction of the first spin-
dle-type machine, the control system
has evolved through many stages to a
full PLC-based implementation. The
last machines produced by Maag used
Modicon equipment. The original
intent of the PLC initiative was to
provide a degree of separation between
the logic and the hardware. A secondary
benefit was the capability to use soft-
ware tools for troubleshooting. With
this system, since the logic (software)
rarely changes, new hardware elements
can readily replace obsolete elements.
Nova has continued the development of
the Maag control system by migrating it
to a PAC (Programmable Automation
Controller) platform. With this tech-
nology, it is possible to install a control
system to adequately operate the shaper
in present time, but also provide the
potential to add full CNC capabilities
as future needs arise. The PAC solu-
tion additionally provides capabilities
for display of machine status, storage
of part production setups and diag-
nostic information. These systems are
designed using a Fieldbus digital I/O
protocol that allows locating the physi-
cal inputs and outputs on the machine.
This eliminates the gaggle of wires run-
ning through the flex conduits back to
the main control. The updated control
will free up at least half of the real estate
in the former control cabinet.
From a gear maker’s view, the upgraded
machine changes very little. The pen-
dant controls are exactly the same. The
main operator panel is modified to
allow the installation of an electronic
display. This display/data entry key-
board annotates machine status and
fault information. Because of the mod-
ular nature of the Nova solution, a ram-
drive-only retrofit can be implemented
on an existing Maag control system and
be completely compatible with a future
PAC upgrade. This interim ram drive
upgrade would be seamless as far as the
operator is concerned.
Nova designs and builds the systems in
Milwaukee, WI. This location provides
a geographical center point for the dis-
patch of service engineers if needed for
further maintenance. After shipment to
the final destination, either plant per-
sonnel or an electrical contractor famil-
iar with the site does the installation.
This has worked well because it allows
a local presence and familiarity with
the hardware. Following the installa-
tion, a factory-trained engineer would
commission the retrofit. In some cases,
owners elect to separately contract the
services of a gear shaper expert to check
and resolve any mechanical issues. In
the case of a ram drive power change,
it is highly recommended that such an
expert be involved because the overload
clutch will have to be adjusted.
A Maag gear shaper is a symphony
of gears, levers, motors, pumps and con-
trol units all playing together in perfect
harmony. A successful retrofit will keep
the parts playing together perfectly. 
For more information:
Nova Systems Inc.
11629 W. Dearbourn Ave.
Milwaukee, WI 53226
Phone: (414) 771-4800
Fax: (414) 771-4847
Internet: www.novasystemsinc.com
Kenn Anderson is vice president of en-
gineering at Nova Systems Inc. and is
responsible for troubleshooting prob-
lems with motors and electronic
controlling devices and for management
of technical personnel. Prior to that, he
was engineering/plant manager for Dietz
Electric Co. in Milwaukee, WI.
Name:
Bob Sakuta, President of Delta Research and Tifco Gage and Gear,
Livonia, MI.
About your career in the gear industry: About your career in the gear industry:
“My dad started the company in 1952. I began working here
when I was 10 or 12. Then I went off to college, got a business
degree and became a ‘big shot’ at a large corporation, but it was
a hollow experience. So I came back to the family business and
have been here ever since.”
What keeps you going? What keeps you going?
“I love building things...the creativity of the business. The
people who work here–they're family.”
Your equipment and technology? Your equipment and technology?
“We have millions worth of gear cutting and grinding machines,
inspection equipment, machining centers, broaching and spline
rolling... to name a few. We usually buy two of everything, just
to have a backup. Recently, we installed a completely auto-
mated gear production cell that runs 24/7 and produces 3,000
gears a day for a customer in Japan. I'm constantly on the hunt
for new equipment and technology.”
The future of the gear industry? The future of the gear industry?
“I have a vision to make Livonia the gear capital of the world!
A cooperative effort with other gear designers and producers
that would provide the innovation and production capabilities
to supply major OEM's and compete globally.”
Your thoughts on Your thoughts on Gear Technology Gear Technology magazine: magazine:
“It's a great magazine. I've been reading it my whole career. It
gives me ideas on how to make better gears. It helps me find the
equipment I need to build the best gears.”
Gear Technology. The magazine gear industry
buyers rely on.
The Journal of Gear Manufacturing
To learn more about Gear Technology, visit www.geartechnology.com or call 847-437-6604.
Reader Profile:
GEAR TECHNOLOGY
42 Gear Product News April 2006 42 Gear Product News April 2006
news
Ajax Tocco
ACQUI RES ASSET S OF T WO
COMPANI ES, MERGES OPERAT I ONS
WI T H GERMAN F OUNDRY
Ajax Tocco Magnethermic purchased the assets of
Lectrotherm and Premelt Systems, both of Canton, OH.
Ajax Tocco Magnethermic GmbH also merged operations
with Foundry Services of Hemer, Germany.
According to Ajax’s press release, Foundry Services will
continue operation in its current location and expand into an
existing Ajax Tocco service center in Sinsheim, Germany.
Lectrotherm specializes in aftermarket repair and replacement
of melting furnaces and electromagnetic stirring ﬁxtures. In
recent years, the company has expanded to provide capital
equipment to non-traditional induction markets.
Premelt Systems designs and services integrated metal scrap
cleaning and processing systems to the aluminum wheel
industry worldwide. 
Timken
SUPPL I ES T WO MI L L I ONT H SPECI AL
BEARI NG ASSEMBL Y T O Z F
The Timken Co. delivered its two millionth special bearing
assembly to the Saarbruecken, Germany, production plant
of ZF, a leading global supplier for automotive driveline and
chassis technology.
The product is a two-row ﬂanged pinion bearing assembly
referred to as a “TDOF.” ZF and Timken have been working
together for years on providing higher performance with
fewer components. The assemblies were ﬁrst featured in
ZF’s four-speed inline automatic transaxles and continued
to evolve with the ﬁve-speed version. It is currently used in
the six-speed automatic transmission cluster for front-wheel,
standard or all-wheel-drive solutions and torques up to 750
Newton-meters. ZF’s transaxles are featured in dozens on
engine-transaxle combinations for a variety of different
car platforms. 


Suzlon Energy
ACQUI RES HANSEN T RANSMI SSI ONS
Suzlon Energy Ltd. of India has acquired gearbox
manufacturer Hansen Transmissions of Belgium from Allianz
Capital Partners for 465 million euros. The acquisition is part
of Suzlon’s growth strategy in the wind turbine manufacturing
market.
“Hansen will be run as an independent business unit,” says
Tulsi R. Tanti, president of Suzlon’s board of directors. “The
acquisition enables Suzlon to integrate gearbox technology in
the development of wind turbines.”
Hansen has two production sites in Belgium, including a new
factory dedicated to the production of wind turbine gearboxes.
Hansen is able to produce gearboxes for 3,600 megawatts of
wind turbines annually.
In addition to its wind turbine manufacturing, Hansen also
has a strong presence in the industrial gear drive market,
manufacturing and assembling more than 3,000 industrial
gearboxes per year for applications such as water treatment,
material handling and cooling towers.
“The acquisition conﬁrms Suzlon’s trust and conﬁdence
to further develop Hansen,” says Matts Lundgren, CEO
of Hansen. “We will continue to manage Hansen as an
independent business unit and strive to exceed customer
expectations.” 

April 2006 Gear Product News 43 April 2006 Gear Product News April 2006 Gear Product News
WE BUY GEAR MACHINES
Gear Hobbers, Shapers, Grinders, Sharpeners, Shavers,
Any Gleason Equipment, and Spline Rollers.
WANT TO FREE UP SHELF SPACE?
WE WANT TO BUY YOUR GLEASON INDEX PLATES, CONIFLEX AND
HYPOID CUTTER BODIES, CAMS, GEARS, AND SPARE
PARTS, SURPLUS TOOLING, EQUIPMENT AND
GEARS FOR ANY GEAR MACHINERY.
E-mail or fax us
a list of your surplus, with photos.
Ph: 847-437-6600
Fax: 847-437-6618
E-mail: [email protected]
CADILLAC MACHINERY CO., INC.
1401 Lunt Ave., Elk Grove Village, IL 60007 USA
Star SU and
Winco Industries
ACQUI RE MARKET I NG AND
MANUF ACT URI NG RI GHT S
F OR BENCERE PRODUCT S
manufacturing rights to a patented series of padded adjustable
reamers and ﬁne boring tools.
The patents, held by Bencere Ltd. of Oxfordshire, England,
are for R-Max padded adjustable reamers and Quattro-Cut
padded ﬁne boring tools. Star SU will become the exclusive
marketer of both products in North America and Winco the
exclusive marketer in South America.
Star SU R-Max reamers can be utilized for close tolerance
reaming of ferrous and non-ferrous parts. Production
tolerances of 0.01 mm or less can be expected. The patented
single clamping screw simpliﬁes ﬁne adjustments to size and
back taper. Automotive and heavy equipment component part
manufacturers utilize these tools for operations such as engine
cam and crank reaming in both cast iron and aluminum
blocks and cylinder heads. Additional applications, such as
steering gears, housings, hydraulic pumps, control valves and
cylinders, air conditioning, compressors, brake calipers and
master cylinders, also typically require precision reaming. 

Metaldyne
SEL L S F ORGI NG BUSI NESS,
HI RES NEW VP
Metaldyne entered into an asset purchase agreement with
Forming Technologies related to the acquisition of Metal-
dyne’s North American forging business.
According to Metaldyne’s press release, it expects $129 million
and the assumption by the buyer of $7.5 million in outstanding
indebtedness of the forging business as well as assumption of
all working capital items and speciﬁc liabilities.
Metaldyne’s North American forging business includes its
operations in Royal Oak, Fraser, Detroit and Troy, MI; Canal

continued
44 Gear Product News April 2006 44 Gear Product News April 2006
news

Balzers
ASSUMES COAT I NG OPERAT I ONS OF
GOL D ST AR COAT I NGS
Balzers announced plans to take over the PVD coating
operations of Gold Star Coatings, a subsidiary of Star
Cutter Co.
According to Balzers’ press release, the transaction will be
completed by April 30. Balzers will assume the function of
coating partner for the tool resharpening services sold by Star
and SU. In addition, Balzers will open an in-house coating
center in the gear tool manufacturing operation of Star Cutter
Co. in East Tawas, MI.
The existing coating center of Gold Star Coatings in
Richmond, IN, will be expanded to become a signiﬁcant
regional site for Balzers. The activities of Gold Star’s West
Branch, MI, facility will be integrated into three existing
Balzers coating centers in Michigan. In the future, Balzers
will have a network of 14 sites in the U.S. and Canada for
contract coating as well as three in-house coating centers
located on customer premises.
Kent Connell, president of Balzers, said, “We are very excited
with the possibility of working much closer with Star SU
and Star Cutter Co. than we have in the past. They are
doing a great job in offering customers a complete package
of tool management and maintenance. We are happy to be
the primary source for coating tools in this package. We are
also excited to add the Gold Star customers to our portfolio
and pledge ourselves to do everything possible to provide
them with outstanding service and excellent quality.” 

Ikona Industries
SHI PS F I RST GEARBOX
MANUF ACT URED I N- HOUSE
Ikona Industries is moving a number of projects from the
initial design and prototype stages into commercialization.
Laith Nosh, president and CEO, said, “This month marks
a signiﬁcant milestone for Ikona as we shipped the ﬁrst
commercial gearbox application completely designed
and manufactured in-house by Ikona Industries. The
application, a satellite antenna base pedestal, is essentially a
gearbox that provides rotation and tilt for a mobile satellite
base station. The application represents approximately
$110,000 in revenue and is soon to be followed by
the shipment of identical units in the coming weeks.”
Formerly known as Ikona Gear, the company recently
announced its name change to Ikona Industries Inc. 
Fulton and Minerva, OH; and Fort Wayne, IN.
Metaldyne also named Marjorie Sorge as vice president of
communications. She will be responsible for development
and maintenance of all internal and external communication
strategies. 

April 2006 Gear Product News 45 April 2006 Gear Product News April 2006 Gear Product News
We have 50,000 square feet with literally hundreds of all types of modern gear equipment.
See our website for a complete inventory of our gear machine tools, most with
photos, and an individual inventory of our gear tooling and accessories.
Fax or E-mail your requirements:
Ph: 847-437-6600
Fax: 847-437-6618
[email protected]
www.cadillacmachinery.com
FLYING INTO CHICAGO?
VISIT US NEXT TO O’HARE AIRPORT
Visiting on business? Attending an auction?
First or last — visit Cadillac Machinery
CADILLAC MACHINERY CO., INC.
1401 Lunt Ave., Elk Grove Village, IL 60007 USA
HELP WANTED
Immediate Openings
for
Shaping and Hobbing Set-Up Technicians
Three years experience preferred
Generous Benefits Package
Small and friendly firm located in
the heart of God’s country in a rural setting
between Milwaukee, Madison and Chicago.
Send Resumes to
Mr. Everett Hawkins
Forest City Gear Company
11715 Main Street, P.O. Box 80
Roscoe, IL 61073

Balzers
OPENS NEW COAT I NG CENT ER
Balzers Inc. opened a coating center in Houston and has
begun coating production of cutting, forming, molding tools
and precision components. This is the fourth center to open
in the past 12 months.
The Houston location will service the South Central region,
including Texas, Oklahoma, Arkansas and Louisiana.
According to the company’s press release, the center will provide
full service coating solutions not only for standard coatings
like titanium nitride but also advanced, high performance
coatings and pre- and post-treatment capabilities.
According to Balzers’ press release, the new Houston center
will primarily serve the cutting tool industry, as well as the
die casting, stamping, forming, mold and die markets for
application in oil ﬁeld services, aerospace, machine tools and
high-wear machine components. 
WE BUY & SELL GEAR EQUIPMENT
ANYWHERE IN THE WORLD
See Complete List of individual tools
and photos at www.cadillacmachinery.com
TESTERS ROLLING
Beaver 2203 3"
Hofler ZW400, 16" 1990
ITW 2203 3"
Parkson 9N, w/ & w/o worm attachment
Parkson 15N 15"
Parkson 24"/30", w/ & w/o worm attachment
Quaker 2-2/2"
SPLINE MILLERS
Barber Colman 16-16, 1966
Hurth KF32a, AMT 4 - 150 Heads,
AMT 4 - 240 Heads, with & without extension,
as late as 1980
Hurth LKF33, 40" Travel, 97" CC, 1970
SPLINE ROLLERS
Michigan 3237, Auto-Loader, 1966
Marand 350, 55" Stroke, 40 HP 1981, rebuilt 1994
Marand 350-S, 55" Stroke, 40 HP 1981, rebuilt GEAR GRINDERS
Kapp VAS 385, 1983
Reishauer AZA, ZB, DS, 1982
Reishauer AM & AM-10 Dressers, 1982
GEAR SHAPERS
Barber Colman 10-4, with Tilt, as late as 1973
Fellows No. 7, 1973
Fellows 10-2, 10-4, 1977 Tailstock Available
WORM HOBBERS/MILLERS
Barber Colman 18-30, 4-cut, 12" Cutter, 1967
Gould & Eberhardt #20 TWG
Spiral Generators #40, 102, 106, 116 Rougher, 116 Finisher, 118, 121, 26, 606 Auto, 607 Auto, 606
Manual, 607 Manual, 615, 616, 642, 645, 650, 950 — to 1983
Straight Generators 3", 24, 24A, 104, 725 — to 1975
Cutter Sharpeners #12, 13A, 496, 532, 538, 545, 563 — to 1981
Grinders 29, 105, 120, 463 — to 1968
Testers #4, 6, 13, 14, 17M, 61, 512, 519 — to 1970
Lappers #15, 500 HL, 503, 514, 516 — to 1996
Cutter Inspection/Setting #15, 527, 528, 563 — to 1981
Quenching Presses #529 Automatic (250 mm), 529 Manual (400 mm), 537 (711 mm)
GLEASON BEVEL EQUIPMENT
Barber Colman 6-10, Plain & Multicycle, 3, 6 & 9 Std. Thread, Single & Triple Precision
Thread, Power Downfeed, as late as 1975
Barber Colman, 14-15, 1 & 2 Thread, 2-Cut, Crowning, std, power & rotating tailstock, 1957-68
Barber Colman, 16-16 Manual, Autocycle, Multicycle, Differential, 1-, 2- & 4- Thread as late as 1980
Barber Colman 16-36, 2-Thread, with differential, as late as 1979
Gleason 775, 6" Capacity, 8.5" Face, 4DP, Auto-Load for Cylindrical Gear - Last job produced 3
parts/minute with load/unload, as late as 1986
Gould & Eberhardt 36 H, 1965
Lambert 109, 6 mm cap., 1976
Lees Bradner 12HD, 1972
Liebherr L650, 2 Cut, crowning, 1976
Mikron A2 1/2, 40 mm Capacity, loader
Pfauter P400, 2 Cut, Sp/Fd change, H.S., 1973
Pfauter P403, 500 mm Capacity, 2-Cut, with Speed & Feed Change in 2
nd
Cut, (choice) 1980
GEAR HOBBERS
HOB SHARPENERS
Barber Colman 6-5, 10-12, Auto Dress, as late as 1982
Kapp AS203, AS305, AS305B
GEAR TESTERS
Lead—Goulder 3H 1973
Involute—Fellows 24M, ITW 3412B, 3424B, as late
as 1981
Combination Lead/Involute—Maag SP60, PH100,
as late as 1981, M & M #3012, ‘00
TESTERS MISCELLANEOUS
Gleason 412 - 60" Curvic Coupling Checker, 1970
Hofler UP630 Pitch Tester, 1987
Hofler HS-1000 Pitch Tester w/ EVTM & SRA, 1972
Maag IMT, MT30, MT11
Maag TML, TMC, TMI Hand-Held Pitch Testers
PROFILATORS
WERA RS5-150, Spline & face cutting, 1981
WERA RM-120, Splines, gears, sprockets, 1995
WERA RM-130, Face couplings, hex, squares, flats
slots & front serrations - near-new—1999
Thousands of Gleason Straight & Spiral Cutter Bodies & Holders, Change Gears for most
models, Index Plates, Genevas, Lift & Drop Cams, Gages, Work Spindle Adaptors, Stock
Dividers, Rebuilt Cutter Spindles, Dresser Arms — check our website for our inventory
GLEASON TOOLING
TOOLING
Index plates, change gears, hob arbors, sharpening
arbors, cutter adaptors, grinding hubs etc. for Barber
Colman, Fellows, Liebherr, Pfauter, Lees-Bradner, Gould
& Eberhardt, Kapp, Hurth, Reishauer and more ...
The Standard of the Gear Industry
Phone: 847-437-6600 • Fax: 847-437-6618
[email protected]
www.cadillacmachinery.com
CADILLAC MACHINERY CO., INC.
1401 Lunt Ave. • P.O. Box 1405
Elk Grove Village, IL 60007 USA
Since 1950
classi fi eds
April 2006 Gear Product News 47 April 2006 Gear Product News April 2006 Gear Product News
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www.gearproductnews.com
The complete issue,
every issue, always available online
Plus
● Subscriptions
● Advertising Information
● FREE Buyers Guide Listings
Bookmark Us Today!
H
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A/W Systems Co. is your quality alternative manufacturing source of
spiral gear roughing and finishing cutters and bodies.
We can also manufacture new spiral cutter bodies in
diameters of 5" through 12" at present.
A/W can also supply roughing and finishing cutters for
most 5"–12" diameter bodies.
Whether it’s service or manufacturing, consider us as an
alternative source for cutters and bodies.
You’ll be in for a pleasant surprise.
1901 Larchwood
Troy, MI 48083
Tel: (248) 524-0778 • Fax: (248) 524-0779
Experts in CNC controlled
tooth by tooth submerged process
gear hardening. We specialize in
precision induction hardening of all
power transmission components.
Registered to TS16949:2002
standards.
Magnum Induction Inc.
14 Ash Drive • Smiths Creek, MI 48074
Ph: 810.364.5270 • Fax: 810.364.4114
Email: [email protected]
magnuminduction.com
“GEARS
FOR A YEAR”
Puts your
message here
... and in
Gear Technology
... and
Online at
geartechnology.com
or
powertransmission.com
Call
Ryan King
at
(847) 437-6604
48 Gear Product News April 2006 Gear Product News April 2006 Gear Product News April 2006
adverti ser i ndex
A/W Systems Co.
Page 47
(248) 524-0778
Arrow Gear Co.
Page 13
(630) 969-7640
www.arrowgear.com
B&R Machine & Gear Corp.
Inside Back Cover
(731) 456-2636
[email protected]
www.brgear.com
Bourn & Koch
Page 22
(815) 965-4013
[email protected]
www.bourn-koch.com
The Broach Masters Inc.
Page 14
(530) 885-1939
www.broachmasters.com
Cadillac Machinery Co. Inc.
Pages 43, 45, 46
(847) 437-6600
[email protected]
www.cadillacmachinery.com
Clifford-Jacobs Forging Co.
Back Cover
(217) 352-5172
[email protected]
www.clifford-jacobs.com
Comtorgage Corp.
Page 9
(401) 765-0900
[email protected]
www.comtorgage.com
Fässler Corp.
Page 10
(414) 769-0072
[email protected]
www.faessler-ag.ch
First Gear
Page 17
(260) 490-3238
www.first-gear.com
Forest City Gear
Page 45
(866) 623-2168
www.fcgear.com
Gear Consulting Group
Inserted Card
(259) 523-4993
[email protected]
www.gearconsultinggroup.com
Gear Manufacturing Inc.
Page 47
(800) 773-4327
www.gearmanufacturing.com
Gear Technology magazine
Pages 31, 41, 47
(847) 437-6604
[email protected]
www.geartechnology.com
gearproductnews.com
Page 47
(847) 437-6604
[email protected]
www.gearproductnews.com
Gleason Corp.
Inside Front Cover
(585) 473-1000
[email protected]
www.gleason.com
James Engineering
Page 21
(303) 444-6787
www.james-engineering.com
Kapp Technologies
Page 3
(303) 447-1130
[email protected]
www.kapp-usa.com
Kleiss Gears Inc.
Page 47
(715) 463-5995 x105
[email protected]
www.kleissgears.com
Koepfer America LLC
Page 7
(847) 931-4121
[email protected]
www.koepferamerica.com
LeCount
Page 17
(800) 652-6713
[email protected]
www.lecount.com
Leistritz Corp.
Page 22
(201) 934-8262
[email protected]
www.leistritzcorp.com
Magnum Induction
Page 47
(810) 364-5270
[email protected]
www.magnuminduction.com
Midwest Gear & Tool Inc.
Page 21
(586) 779-1300
[email protected]
powertransmission.com
Pages 13, 23
(847) 437-6604
[email protected]
www.powertransmission.com
Precision Gage Co. Inc.
Page 43
(630) 655-2121
[email protected]
www.precisiongageco.com
Presrite Corp.
Page 12
(216) 441-5990
www.presrite.com
Process Equipment Co.
Page 11
(800) 998-4191
[email protected]
www.gearinspection.com
The Purdy Corp.
Page 37
(860) 649-0000
www.purdytransmissions.com
Sigma Pool
Page 4
(734) 429-7225
[email protected]
www.sigma-pool.com
United Tool Supply
Inserted Card
(800) 755-0516
[email protected]
Machine and Gear Corporation
CUSTOM
BEVEL GEAR MANUFACTURING
Per Your Specifications and/or Sample
Providing Inverse Engineering to Make a Clone of Your Sample
· Spiral Bevel Gears: 66" PD Spiral Bevel Gears: 66" PD
· Straight Bevel Gears: 80" PD Straight Bevel Gears: 80" PD
· Spurs Helicals Spline Shafts Spurs Helicals Spline Shafts
· Gearbox Repair/Rebuilds Gearbox Repair/Rebuilds
· In-House Steel Material In-House Steel Material Warehouse
· Full Heat Treating Services Full Heat Treating Services
· EDM Wire Burning EDM Wire Burning
BREAKDOWN
SERVICES
4809 U.S. Highway 45 Sharon, TN 38255
Toll Free: (800) 238-0651 Ph: (731) 456-2636 Fax: (731) 456-3073
E-mail: [email protected] Internet: www.brgear.com
Family owned and operated since 1974

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